Electrical circuit breaker assembly

ABSTRACT

A breaker assembly is disclosed comprising a breaker board having a bus bar including a first engagement feature and a breaker module having a line side connector including a second engagement feature engaging the first engagement feature to inhibit separation of the breaker module from the breaker board. The breaker board can further include a board mount having a first alignment feature, and the breaker module can further include a module mount engaging the board mount and having a second alignment feature engaging the first alignment feature. In another aspect of the invention, the breaker board includes board connections, the breaker module includes breaker connections (e.g., blind mate connections), and the board connections are engaged with the breaker connections. In another aspect of the invention, the breaker module includes a ledge that defines an undercut to facilitate prying of the breaker module from the breaker board.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 61/923,416, filed Jan. 3, 2014, the entire contents of which are incorporated by reference herein.

BACKGROUND

The present invention relates to electrical circuit breakers and methods for using circuit breakers.

Circuit breakers are electrical switches that are commonly used to protect an electrical circuit from damage caused by too much current, such as can result from an overload or short circuit condition. Circuit breakers are typically designed to automatically trip open when an undesired condition is encountered, and they can also be reset to the closed position when the undesired condition is removed.

Some circuit breakers can be controlled (e.g., manually tripped or reset) remotely, while others must be controlled locally (e.g., physically at the breaker). For remotely-controllable breakers, solenoids are often used to facilitate remotely tripping or resetting the breaker.

SUMMARY

The present invention provides a breaker assembly comprising a breaker board having a bus bar including a first engagement feature (e.g., a recess) and a breaker module having a line side connector including a second engagement feature (e.g., a protrusion) engaging the first engagement feature to provide inhibit separation of the breaker module from the breaker board. The first and second engagement features can also provide a tactile and auditory indication (e.g., a snap) that the breaker module has fully seated into the breaker board. Preferably, the line side connector includes two resilient conductors spaced apart a distance less than a thickness of the bus bar. In one embodiment, the breaker board further includes a board mount (e.g., a mounting rail) spaced from the bus bar, and the breaker module further includes a module mount (e.g., a pivot mount) engaging (e.g., pivotally engaging) the mounting rail. The module mount can include a first alignment feature (e.g., an alignment recess), and the board mount can include a second alignment feature (e.g., an alignment web) engaging the first alignment feature.

In another aspect of the invention, the breaker board further includes board connections positioned between the board mount and the bus bar, the breaker module further includes breaker connections positioned between the module mount and the line side connector, and the board connections are engaged with the breaker connections. Preferably, the breaker connections are blind mate connections positioned along a back side of the breaker module.

In another aspect of the invention, the line side connector is adjacent a first end of the breaker module, the module mount is adjacent a second opposing end of the breaker module, and the breaker module further comprises a ledge positioned adjacent the first end (e.g., adjacent a front side of the breaker module). The ledge preferably defines an undercut that facilitates prying of the breaker module from the breaker board.

Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a circuit breaker assembly embodying the present invention.

FIG. 2 is an enlarged perspective view of the assembly of FIG. 1 showing a single breaker module mounted to the breaker board.

FIG. 3 is an enlarged view of FIG. 2.

FIG. 4 shows the breaker module of FIG. 2 exploded from the breaker board.

FIG. 5 shows the breaker module of FIG. 4 partially inserted into the breaker board.

FIG. 6 shows a different view of the assembly of FIG. 5.

FIG. 7 shows the assembly of FIG. 6 with the breaker module fully seated into the breaker board.

FIG. 8 is a perspective view of a mounting rail on the breaker board.

FIG. 9 is another view of the mounting rail of FIG. 8.

FIG. 10 is a top view of the mounting rail of FIG. 8.

FIG. 11 is a side view of the mounting rail of FIG. 8.

FIG. 12 is a perspective view of the breaker module with half of the housing removed.

FIG. 13 is another perspective view of the breaker module of FIG. 12.

FIG. 14 is another perspective view of the breaker module of FIG. 12.

FIG. 15 is a perspective view showing removal of a breaker module from the breaker board.

FIG. 16 is a partial perspective view of a breaker board corresponding with a second embodiment of the invention.

FIG. 17 is a different partial perspective view of the breaker board of FIG. 15.

FIG. 18 is a perspective view of a breaker module designed to fit into the breaker board of FIGS. 15-16.

FIG. 19 is a different perspective view of the breaker module of FIG. 17.

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

DETAILED DESCRIPTION

FIG. 1 is a perspective view of a circuit breaker assembly 20 embodying the present invention. The assembly 20 includes a housing 22, a breaker board 26, breaker modules 28, a controller 30 having a control panel 32, and control circuitry 34. The illustrated housing 22 is shown with several panels removed. Many of these parts can be provided with off-the-shelf parts, but the breaker board 26 and breaker modules 28 in this embodiment are specifically designed to achieve the benefits of the present invention.

Referring to FIGS. 1 and 2, the illustrated breaker board 26 includes forty-eight stations 38, including twenty-four stations along one side of the assembly and another twenty-four stations along the other side of the assembly. As such, it can be seen that each station 38 has a station 38 horizontally aligned with it to thereby create a pair of aligned stations. The stations 38 are divided into three different groups: left phase, center phase, and right phase, and each pair of horizontally aligned stations (i.e., directly across from each other, back-to-back) has the same phase. The groups of stations are arranged in an alternating pattern with the lowest pair of stations being right phase, the next pair of stations being center phase, the next pair of stations being left phase, and so on.

As shown in FIGS. 3-7, each station 38 includes a back surface 40, a board mount in the form of a mounting rail 42, a bus bar 46, and an insulating wall 48. Each back surface 40 includes board connections 50 for providing electrical communication between the controller 30 and the breaker module 28. Referring to FIGS. 8 and 9, each mounting rail 42 includes a rail member 52 having a cylindrically curved convex surface 54 that facilitates pivoting of the breaker module 28 as it is being mounted on the breaker board 26, as described below in more detail. The back surface 40 includes a recess 56 behind each mounting rail 42. Each mounting rail further includes an alignment web 58 extending between the rail member 52 and the recess 56 to facilitate alignment of the breaker module 28 in the station 38, as described below in more detail. The outer surface of each mounting rail 42 includes reinforcement flanges 60, and the sides 62 of each mounting rail 42 are tapered to facilitate insertion of the breaker module 28 into the station 38.

The bus bar 46 of each station 38 is integrally connected to the bus bar 46 of the horizontally aligned station 38 such that the pairs of stations are in a back-to-back orientation and share a common bus bar 46. Each bus bar 46 includes an engagement feature in the form of a hole 64 (see FIGS. 3 and 7) that facilitates positive engagement of the corresponding breaker module 28, as described below in more detail.

Each breaker module 28 includes a breaker housing 66, a reset lever 67 on a front side of the housing 66, an array of breaker connections 68 on a back side of the housing 66, a module mount in the form of a pivot mount 70 positioned adjacent the front side and a second end of the breaker housing 66, and a line side connector 72 positioned adjacent the back side and a first end of the breaker housing 66. In FIGS. 2-7, part of the breaker housing 66 has been truncated in order to more clearly show the line side connector 72. In FIGS. 12-14, half of the breaker housing 66 has been omitted. The breaker housing 66 contains the electrical components 74 of the breaker module 28. The breaker connections 68 are low-voltage connections that facilitate electrical communication between the controller 30 and the breaker module 28 when the breaker module 28 is mounted in the corresponding station 38. As shown in FIGS. 12-14, the breaker connections 68 are positioned between the pivot mount 70 and the line side connector 72 along the back side of the breaker module 28. In this regard, the board connections 50 and breaker connections 68 are blind mate connections that are not accessible when the breaker module 28 is mounted to the breaker board 26.

The pivot mount 70 includes two pivot members 76, each having a cylindrically curved concave surface 78 (FIG. 12) adapted to engage the convex surface 54 of the corresponding rail member 52. The pivot members 76 are separated by an alignment recess 80 dimensioned to receive the alignment web 58 when the breaker module 28 is mounted to the breaker board 26 in order to insure proper alignment of the breaker module 28 relative to the station 38.

The line side connector 72 includes two resilient conductors 82 spaced apart from each other by a distance D (see FIG. 14) that is less than a thickness T (see FIG. 7) of the bus bar 46. Each resilient conductor 82 includes an engagement feature in the form of a raised boss 84 (see FIGS. 13-14) adapted to fit into the hole 64 of the corresponding bus bar 46 in order to provide a tactile or audible indication that the breaker module 28 is fully seated into the corresponding station 38. The interaction between the boss 84 and the hole 64 can also hold the breaker module in place and prevent unwanted movement between the breaker module 28 and the bus bar 46.

Immediately above (i.e., away from the line side connector 72, the breaker housing 66 includes a cut-out 77 that creates a vent channel for the venting of plasma. The cut-out 77 has a depth D1 that is approximately the same as a Depth D2 of the conductors 82 (FIG. 12). In addition, the cut-out 77 has a height H1 that is at least as large, and preferably larger than, the height H2 of the conductors 82 (see FIG. 5).

In operation, a breaker module 28 is inserted into a station 38 by first inserting the pivot members 76 under the rail member 52 with the alignment web 58 being received in the alignment recess 80. The breaker module 28 is then pivoted downward toward the back surface 40 of the station 38, thereby bringing the line side connector 72 into engagement with the corresponding bus bar 46. Further downward pivoting of the breaker module 28 results in the bus bar 46 being received between the two resilient conductors 82 until the raised bosses 84 snap into the hole 64 in the bus bar 46. Coupling the breaker module 28 to the station 38 in this manner will inherently result in the breaker connections 60 beings electrically coupled to the board connections 50 to facilitate communication between the controller 30 and the breaker module 28.

Referring to FIG. 15, the breaker module 28 includes a ledge 75 that facilitates disengaging the beaker module 28 from the breaker board 26. Specifically, the ledge 75 creates an undercut adapted to receive a pry bar, such as a flat head screwdriver, that can be leveraged off the adjacent breaker module in order to facilitate disengagement of the resilient conductors 82 from the corresponding bus bar 46.

Each breaker module 28 is a fully magnetic breaker with solenoid-actuated load switching and three positions—on, off, and tripped. Each breaker module 28 can be manually moved to the on or off positions at any time. The circuit breaker assembly 20 can also be controlled by the controller 30 that is remote from the breaker modules 28. The controller 30 receives information from a variety of sources and uses that information to determine the operating characteristics of the breaker assembly 20. For example, the controller 30 can receive commands (e.g., over a wired network or wirelessly over a wi-fi network) that dictate the operating parameters (e.g., whether to turn on, off, or re-set) of one or more breaker modules 28. The illustrated controller 30 is programmed to prevent the remote re-setting of a breaker module 28 if the breaker module 28 was tripped. In other words, when one of the illustrated breaker modules 28 is tripped, it can only be reset manually at the breaker module 28. In addition, the controller 30 allows the breaker to be turned on manually even if the breaker module 28 was turned off or tripped remotely (e.g., even if the controller dies).

FIGS. 16-17 illustrate an alternative breaker board 86 having a back surface 88 with board connections 90 that are positioned in a well 92 (i.e., offset from a plane defined by the back surface 88). Two raised stanchions 94 are positioned in the well 92.

FIGS. 18-19 illustrate an alternative beaker module 95 having a bottom surface 96 and a protruding platform 97 that contains breaker connections 98 adapted to engage the board connections 90 when the breaker module 95 is mounted to the breaker board 86 of FIGS. 16-17. The platform 97 includes recesses 99 dimensioned to receive the stanchions 94 when the breaker module 95 is mounted to the breaker board 86.

Thus, the invention provides, among other things, a breaker assembly 20 having breaker modules 28 that can be easily snapped into place and that provides remote control capabilities while limiting remote reset when the breaker has tripped and allowing full manual control at the breaker module 28. Various features and advantages of the invention are set forth in the following claims. 

1. A breaker assembly comprising: a breaker board having a bus bar including a first engagement feature; and a breaker module having a line side connector including a second engagement feature engaging the first engagement feature to inhibit separation of the breaker module from the breaker board.
 2. The breaker assembly of claim 1, wherein one of the first engagement feature and second engagement feature comprises a recess and the other of the first engagement feature and second engagement feature comprises a protrusion.
 3. The breaker assembly of claim 1, wherein the first engagement feature comprises a recess in the bus bar.
 4. The breaker assembly of claim 1, wherein the second engagement feature comprises a protrusion on the line sided connector.
 5. The breaker assembly of claim 1, wherein the line side connector includes two resilient conductors spaced apart a distance less than a thickness of the bus bar.
 6. The breaker assembly of claim 1, wherein the breaker board further includes a mounting rail spaced from the bus bar, and wherein and the breaker module further includes a pivot mount pivotally engaging the mounting rail.
 7. The breaker assembly of claim 6, wherein the pivot mount includes a first alignment feature and the mounting rail includes a second alignment feature engaging the first alignment feature.
 8. The breaker assembly of claim 7, wherein the first alignment feature comprises an alignment recess and the second alignment feature comprises an alignment web positioned in the alignment recess.
 9. The breaker assembly of claim 6, wherein the breaker board further includes board connections positioned between the mounting rail and the bus bar, wherein the breaker module further includes an array of breaker connections positioned between the pivot mount and the line side connector, and wherein the board connections are engaged with the breaker connections.
 10. The breaker assembly of claim 9, wherein the breaker connections are positioned along a back side of the breaker module.
 11. The breaker assembly of claim 6, wherein the line side connector is adjacent a first end of the breaker module and the pivot mount is adjacent a second opposing end of the breaker module, and wherein the breaker module further comprises a ledge positioned adjacent the first end.
 12. The breaker assembly of claim 11, wherein the ledge is adjacent a front side of the breaker module.
 13. The breaker assembly of claim 11, wherein the ledge defines an undercut that facilitates prying of the breaker module from the breaker board.
 14. A breaker assembly comprising: a breaker board having a bus bar, a board mount spaced from the bus bar, and board connections positioned between the bus bar and the board mount; and a breaker module having a line side connector adapted to engage the bus bar, a module mount adapted to engage the board mount, and breaker connections positioned between the line side connector and the module mount and adapted to be engaged with the board connections.
 15. The breaker assembly of claim 14, wherein the breaker connections are positioned along a back side of the breaker module.
 16. The breaker assembly of claim 14, wherein the breaker connections are blind mate connections positioned along a back side of the breaker module.
 17. The breaker assembly of claim 14, wherein the line side connector is adjacent a first end of the breaker module and the module mount is adjacent a second opposing end of the breaker module, and wherein the breaker module further comprises a ledge positioned adjacent the first end.
 18. The breaker assembly of claim 17, wherein the ledge is adjacent a front side of the breaker module.
 19. The breaker assembly of claim 17, wherein the ledge defines an undercut that facilitates prying of the breaker module from the breaker board. 